U.S. patent number 4,951,379 [Application Number 07/412,316] was granted by the patent office on 1990-08-28 for method for connecting wires to terminals having tangs and cutting the wires at the terminals.
This patent grant is currently assigned to Globe Products Inc.. Invention is credited to Gary E. Clemenz.
United States Patent |
4,951,379 |
Clemenz |
August 28, 1990 |
**Please see images for:
( Certificate of Correction ) ** |
Method for connecting wires to terminals having tangs and cutting
the wires at the terminals
Abstract
A method of connecting a wire segment, such as a stator coil
lead, to a terminal having a tang and severing the wire segment at
the terminal including the steps of gripping the wire segment by
gripper jaws of an industrial robot, manipulating the gripper jaws
to lay the wire segment between one side of the tang and the
adjacent face of the terminal, loop the wire segment around an edge
of the tang, extend it past the tang, bend it over an edge of the
terminal, and pull it with sufficient force that it stretches and
breaks at a corner of the terminal edge. The wire segment is
initially gripped with a sufficiently low pressure that it can
slide along the gripper jaws as it is being manipulated to connect
the wire to the terminal. The gripping pressure is increased prior
to the pulling step so that sufficient pressure is applied that the
free end of the wire segment is held clamped and will not be drawn
through the gripper jaws when the wire segment is being stretched
and severed.
Inventors: |
Clemenz; Gary E. (Greene
County, OH) |
Assignee: |
Globe Products Inc. (Huber
Heights, OH)
|
Family
ID: |
23632508 |
Appl.
No.: |
07/412,316 |
Filed: |
September 25, 1989 |
Current U.S.
Class: |
29/597; 310/234;
242/432; 29/598 |
Current CPC
Class: |
H01R
43/00 (20130101); H02K 15/0068 (20130101); H02K
15/095 (20130101); H02K 3/522 (20130101); H02K
15/0056 (20130101); Y10T 29/49012 (20150115); Y10T
29/49011 (20150115) |
Current International
Class: |
H02K
3/46 (20060101); H02K 15/095 (20060101); H01R
43/00 (20060101); H02K 15/08 (20060101); H02K
3/52 (20060101); H02K 15/00 (20060101); H02K
015/09 () |
Field of
Search: |
;29/597,598,7.32,7.36,605 ;242/7.03,7.5B,7.5A,7.5C ;310/234 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
2013533 |
|
Aug 1979 |
|
GB |
|
2092029 |
|
Aug 1982 |
|
GB |
|
Primary Examiner: Hall; Carl E.
Attorney, Agent or Firm: Dybvig; Roger S.
Claims
I claim:
1. A method for connecting a wire segment having a fixed end and a
free end to a terminal having a tang projecting from one face
thereof and a side edge, said method comprising the steps of:
laying a portion of said wire segment between one side of said tang
and said face of said terminal;
looping said wire segment around the other side of said tang;
extending said wire segment past said tang and bending said segment
so that a portion of said segment between said tang and said free
end of said segment is extended over said edge of said terminal;
and
pulling said wire segment with sufficient force that said wire
segment is so stretched that it breaks at a corner of said edge of
said terminal.
2. The method of claim 1 further comprising the step of gripping
said wire segment by gripper means which is controllable to apply
different gripping pressures to said wire segment, initially
gripping said wire segment with a pressure sufficiently low that
said wire segment may be drawn through said gripper means as said
wire segment is being looped around said tang and bent around said
edge, and increasing the gripping pressure applied to said wire
segment by said gripping means after said wire segment is bent over
said edge and before said pulling step so that said wire segment is
gripped with sufficient pressure that said wire segment will not be
drawn through said gripping means when said wire segment is being
broken.
3. A method for connecting a wire coil lead wire extending from a
stator coil wound on a stator core and having a free end relatively
loosely held by a wire clamp to a terminal projecting from an end
face of said stator core and having a tang projecting from one face
thereof and a side edge, said method comprising the steps of:
laying a portion of said coil lead between one side of said tang
and said face of said terminal;
looping said coil lead around the other side of said tang;
extending said coil lead past said tang and bending said coil lead
so that a portion of said coil lead between said tang and said free
end is extended over said edge of said terminal; and
pulling said coil lead with sufficient force it is so stretched
that it breaks at a corner of said edge.
4. The method of claim 3 further comprising the step of gripping
said coil lead by gripper means which is controllable to apply
different gripping pressures to said coil lead, initially gripping
said coil lead with a pressure sufficiently low that said coil lead
may be drawn through said gripper means as said coil lead is being
looped around said tang and bent around said edge, and increasing
the gripping pressure applied to said coil lead by said gripping
means after said coil lead is bent over said edge and before said
pulling step so that said coil lead is gripped with sufficient
pressure that said coil lead will not be drawn through said
gripping means when said coil lead is being broken.
5. For use in the manufacture of electric motor stators of the type
comprising a stator core with pole pieces around which wire coils
are wound, terminal supports mounted on the stator core, and
terminals mounted in and projecting from said terminal, a method
for connecting a wire coil lead wire extending from said stator
coil past said terminal and having a free end held by clamp means
remotely from said stator core, said terminal comprising a sheet
member having substantially parallel first and second faces, a pair
of side edges joining to said faces to form corners therebetween,
and said terminal further comprising a tang projecting from said
first face, said method comprising the steps of:
gripping said coil lead by pressure-controllable gripper means at a
point between said terminal and said free end and nearer said
terminal than said free end with a pressure sufficiently low that
said coil lead may be drawn through said gripper means;
moving said gripper means as needed to lay a portion of said coil
lead between one side of said tang and said first face of said
terminal, to thereafter loop said coil lead around the other side
of said tang, to extend said coil lead past said tang over said
first face, to loop said coil lead over one of said side edges, and
to extend said coil lead along said second face of said
terminal;
increasing the gripping pressure applied to said coil lead by said
gripper means; and
pulling said coil lead with force sufficient that it is stretched
and broken at the corner of said terminal between said last
mentioned side edge and said second face of said terminal.
Description
SUMMARY OF THE INVENTION
This invention relates to a method for connecting wires to
terminals having tangs and cutting the wires at the terminals and
to products produced by the method. The invention is primarily
directed to a method for connecting wire coil leads of electric
motor stators but may be used with numerous other products having
such terminals.
Two pole stators for universal electric motors typically have a
pair of coils comprising magnet wire having an insulating coating
wound around pole pieces formed on a laminated core. Each coil has
two or more wire leads extending therefrom. A practice that has
become commonplace in recent years is to mount terminals having
lead-clamping hooks or tangs on the stator cores adjacent the coils
to which the coil leads are connected. Such a terminal often is in
the form of a flat plate or a U-shaped clip and has a wire-clamping
tang struck outwardly from one of its faces.
In preparation for connection of coil leads to terminals, having
lead-clamping tangs, each of the coil leads may be cut at the end
of the coil winding process with a sufficient length that it can be
held by a stationary wire clamp in a position wherein it extends
across the face of the stator and past its associated terminal so
that it may be mechanically manipulated to be connected to the
terminal. In order to achieve connection of a coil lead to a
terminal, the practice has been to advance a movable wire gripper
toward the coil lead, manipulate the movable gripper to lay the
wire lead in the trough formed between the wire-clamping tang and
the adjacent face of the terminal, peen the tang over the wire lead
so that the lead is clamped between the tang and the adjacent face
of the terminal, cut the wire lead adjacent the terminal, and
retract and open the wire gripper to dispose of the excess wire. In
a later step, usually accomplished at a different processing
station, the coil leads are fused to the terminals by a welder. The
heat of fusion melts the insulating coatings from the wires so that
adequate electrical connections between the coil leads and the
terminals are obtained.
Portions of the foregoing manufacturing processes can be done
manually but the more common practice is to use automatic machines.
The wire handling, tang peening, and wire-cutting mechanisms of
such machines are somewhat complex and the machines are usually
tooled so that each machine is dedicated to the manufacture of but
one stator configuration. If it is desired to use the machine for
manufacturing a differently configured stator, the machine must be
practically completely rebuilt.
An object of this invention is to provide an improved method for
connecting wire segments to terminals having tangs. More
particularly, it is an object of this invention to provide an
improved method for connecting wire coil leads of stator coils to
terminals having tangs.
A further object of this invention is to connect a wire segment,
such as a stator coil lead, to a terminal having a tang with
sufficient security that no additional means or method, such as a
peening operation, is required to hold the wire segment on the
terminal during subsequent processing until the wire segment is
fused to the terminal.
A still further object of this invention is to dispense with the
need in an automatic terminal connecting machine to provide cutting
means to cut a wire segment connected to a terminal.
In an aspect of this invention, the method of connecting a wire
segment to terminal having a tang and severing the wire segment at
the terminal includes the steps of gripping a wire segment having
fixed end and a free end sufficiently near its fixed end that the
stretch of wire between its fixed end and its gripped portion can
be controllably manipulated. (If this stretch of wire is too long,
it may be too flexible or rubbery to enable it to be satisfactorily
handled during the terminal connection and wire cutting process.)
The wire segment may comprise a stator coil lead in which case its
fixed end is at the stator coil and, in a common practice, its free
end is releaseably held by a clamp device stationarily mounted with
respect to the stator core. The gripped wire segment is laid
between one side of the tang and the adjacent face of the terminal,
looped around an edge of the tang, extended past the tang, bent
over an edge of the terminal, and pulled with sufficient force that
it stretches and breaks at a corner of said terminal edge.
Another object of this invention is to provide a method whereby a
wire segment may be connected to a terminal having a tang by an
industrial robot without the need for dedicated tooling specific to
a particular product or device, such as a uniquely configured
stator for electric motors. Accordingly, one industrial robot may
be programmed so that it can make terminal connections and sever
the terminal wires for many different stators or other devices.
During intervals when the robot is not carrying out the method of
this invention, it may also be used for other purposes, such as,
for example, unloading stator cores or other devices.
In a preferred practice of this invention, a wire segment is
gripped by gripper means of an industrial robot which gripper means
is controllable to apply different gripping pressures to the wire
segment. The wire segment is initially gripped with a pressure
sufficiently low that it can slide along the gripper means as it is
being manipulated to connect it to the terminal. The gripping
pressure is increased prior to the pulling step so that sufficient
pressure is applied that the free end of the wire segment is held
clamped and will not be drawn through the gripper means when the
wire segment is being stretched and severed.
To retain optimum control of the stretch of wire between its
gripped portion and its fixed end, the movements of the gripper
means is in directions such that, if possible, the wire segment
would be pulled from its fixed end. Since the wire segment cannot
be pulled from its fixed end, the gripper means slides along the
wire segment toward the free end the wire segment as portions of
the wire segment accumulate on the terminal. Accordingly, the
stretch of the wire segment between its fixed end and its clamped
portion remain taut throughout the wire connection and severing
process.
Other objects and advantages will become apparent from the
following description and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified and fragmentary perspective view of a wound
stator with coil leads extending from the coils wound thereon, a
support for the stator, stationary wire clamps for holding the coil
leads, and a portion of a robot for connecting the coil leads to
terminals on the stator core in accordance with this invention. The
parts are shown positioned in FIG. 1 preliminary to connecting the
leads to the terminals.
FIG. 2 is an enlarged, fragmentary perspective view of a portion of
the stator of FIG. 1 and a portion of the robot and illustrates a
first step in the method of connecting a coil lead to a terminal
and severing the coil lead in accordance with this invention.
FIGS. 3 through 8 are enlarged, fragmentary perspective views
similar to FIG. 2 and illustrate in succession the steps for
completing the connection of the coil lead to the terminal and the
severing of the coil lead.
FIG. 9 is an end elevational view of the portion of the terminal to
which the wire lead is connected in accordance with this invention
and the coil lead connected thereto.
FIG. 10 is a fragmentary perspective view of a stator having a
terminal configuration that differs from the terminal of the stator
illustrated in FIGS. 1 through 9 and to which a coil lead has been
connected in accordance with the method of this invention.
DETAILED DESCRIPTION
FIG. 1 fragmentarily illustrates one stage of a multi-stage
production line for producing stators for electric motors. The
structure fragmentarily illustrated comprises a stator support
assembly 10 that supports and clamps a stator 12 of the type
comprising a laminated stator core 14 having pole pieces 16 about
which a pair of stator field coils 18 and 20 are wound. At the
production stage illustrated, the stator 12 is only partially
completed and lack terminal connections by which electrical energy
would be supplied to the field coils.
During the terminal connecting and coil lead cutting process
described below, the stator support assembly 10 is stationary.
Those familiar with the art will recognize that the stator support
assembly 10 may form part of a turret or other workpiece handling
machinery by which the support assembly is moved into a station at
which the method of this invention is practiced and thereafter
moved out of the station so that the method can be repeatedly
carried out on successive stators.
As will be understood by those familiar with the art, a number of
operations leading toward completion of the stator 12 have already
been performed. In a preceding manufacturing step, a pair of
terminal boards 22 and 24 were mounted on the stator core 14 in
face-contacting relation to the end face of the stator core 14. It
will be noted that the terminal boards 22 and 24 lie adjacent the
pole pieces 16. The terminal boards 22 and 24 are preferably molded
plastic pieces and have upstanding sockets 26, one of which is
shown enlarged in FIGS. 2 through 8, projecting therefrom. The
sockets 26 project outwardly from the terminal boards 22 and 24 in
a direction generally perpendicular to and outwardly from the
stator core 14.
Prior to the time the coils 18 and 20 are wound, metal terminals 28
are inserted into the sockets 26. The terminals 28 are constructed
to interfit with mating connectors in the final assembly of the
motor of which the stator 12 is a part. Terminals such as this may
have various different configurations. The particular terminal 28
illustrated in FIGS. 1 through 9 comprises a U-shaped spring clip
having a first leg 30 lodged within the socket 26 and second leg 32
that projects out of the socket 26. A terminal tang 34, which may
be struck out of the second terminal leg 32 projects from the outer
face, designated 36, thereof.
Also in a prior production stage, after the coils 18 and 20 are
wound, the wire coil leads, designated 38, 40, 42, and 44,
respectively, extending from the ends of the field coils 18 and 20
are gripped by suitable clamp assemblies 46 fixedly mounted on the
stator support assembly 10. The depiction of the clamp assemblies
46 in FIG. 1 is somewhat simplified since they do not form part of
this invention. They exert clamping pressures on the coil leads
sufficient to retain them oriented as shown in FIG. 1 until the
leads are pulled from the clamps. The clamps may be spring powered
or may be powered by air actuators or other suitable means. Also in
a prior operating stage, the free ends of the coil leads 38, 40,
42, and 44 are cut to the desired length so that their free ends
project beyond the clamps 46.
As a result of the prior operations mentioned above, each of the
coil leads 38, 40, 42, and 44 is extended from its stator coil 18
or 20, across the end face of the stator core 14, past its
respective terminal 28, and through its respective stationary clamp
46. The present invention is concerned with a method by which the
coil leads 38, 40, 42, and 44 are connected to the terminals 28
after the parts have reached the position shown in FIG. 1 and the
excess length thereof severed at the terminals 28.
In its broader aspects, the method of this invention may be carried
out manually but it is particularly intended, for high speed
production purposes, to be carried out by an industrial robot
generally designated 50. The portion of the robot 50 shown in the
drawings includes an arm 52 and a gripper member 54 having a pair
of gripper jaws 56. For reasons which will become apparent, the
gripper jaws 56 are so controlled that the clamping pressures
applied by them can be varied. For example, as will be readily
recognized by those familiar in the art, the gripper jaws 56 may be
controlled by a variable air actuator. Otherwise, the robot 50 may
be entirely conventional and is not further illustrated herein.
Although different types of robots may be useful in the practice of
this invention, a three-axis Cartesian robot, such as is available
from Hirata Corporation of America, 3901 Industrial Blvd.,
Indianapolis, Indiana 46254, is presently preferred.
With reference to FIGS. 1 and 2, a secure connection of the coil
lead 38 to the second leg 32 of its associated terminal 28
commences in accordance with this invention by the advancement of
the robot arm 52 along an axis 58 parallel to the axis, designated
60, of the stator 12 clamped to the stator support assembly 10.
After the robot arm has moved, as indicated by the arrow 62 in FIG.
2, to a position wherein the gripper jaws 56 straddle the coil lead
38, movement of the arm 52 is stopped and the jaws 56 are actuated
to grip the coil lead 38 as shown in FIG. 2. The gripped portion of
the coil lead 38 is between its associated terminal support socket
26 and its free end but much closer to its terminal socket 26 than
to its free end so that the stretch of the coil lead between the
coil from which it extends and the gripper jaws 56 is sufficiently
short that it does not flex or buckle uncontrollably during the
manipulations of the gripper jaws 56.
When the coil lead 38 is first gripped by the gripper jaws 56, the
clamping pressure of the gripping jaws 56 is sufficiently low that
the gripper jaws 56 will slide along the coil lead 38 as portions
of the coil lead 38 are extended over parts of the terminal leg 32.
At a later stage, described below with reference to FIG. 8, the
clamping pressure is increased so that the coil lead is firmly
clamped when the wire lead is stretched and severed against the
terminal leg 32.
The stationary clamp assemblies 46 are preferably operable so that
their grip on the coil leads can be released. If so, the stationary
clamp assembly 46 associated with the coil lead 38 is operated to
release its grip thereon after the coil lead 38 is gripped by the
gripper jaws 56. Optionally, the stationary clamp assemblies 46 may
clamp the coil leads with such a low clamping pressure that it
would not be necessary to release the leads; the leads will simply
be pulled from their respective clamps by subsequent processing
steps.
With the coil lead 38 held clamped by the gripper jaws 56, the
robot arm 52 is manipulated through a continuous series of steps
illustrated in FIGS. 3 through 7 to securely connect the coil lead
38 to the terminal leg 32. The movements of the gripper jaws 56 are
shown sequentially in each of FIGS. 3 through 7, with the starting
position for each figure shown by phantom lines 56A and the ending
position shown by full lines 56. The starting position for each of
FIGS. 3 through 7 is the same as the ending position of each of the
preceding FIGS. 2 through 6, respectively.
In accordance with this invention, the clamp jaws 56 are so
manipulated, as indicated by the arrow 64 in FIG. 3, that the coil
lead 38, which was originally extended below the lower surface of
its socket 26, is bent upwardly around the lower, outer corner 66
of the socket 26 and extended behind a wire-support protuberance 68
located on the outer side face of the socket 26 as shown in FIG.
3.
The coil lead 38 is then extended outwardly from the face of the
stator core 14 along the length of the terminal support socket 26
by a movement of the gripper jaws 56 away from the stator core as
indicated by the arrow 70 in FIG. 4. Many terminals do not have a
wire-support protuberance such as the protuberance 68 and the
manipulation of the coil lead 38 by the jaws 56, as thus far
described, will be unneccessary with many terminals.
FIG. 5 illustrates a key step in the practice of the method in
accordance with this invention by which the gripper jaws 56 are
moved, as indicated by the arrow 72, vertically downwardly and then
horizontally toward the stator core 14 to first lay the coil lead
38 in the trough, designated 74, formed between the tang 34 and the
first face 36 of the terminal leg 32 and to then pull the coil lead
38 toward the stator core 14. In consequence, the segment of the
coil lead 38 is coursed over the tang 34 exerts a pulling force on
the terminal 28 tending to keep it seated within its socket 26.
Here it should be noted that the length of the unsupported stretch
of the coil lead 38 between the the gripper jaws 56 and parts of
the terminal 28 and its socket 26 which are engaged by the coil
lead 38 remains substantially constant throughout the lead
connection process. This is because the gripper jaws 56 slide along
the coil lead 38 toward its free end as needed to accommodate the
lengths of the coil lead 38 coursed over the terminal 28 and its
socket 26. This stretch of wire also stays relatively taut because
all of the movements of the gripper jaws are in a direction tending
to pull the coil lead 38 from its fixed end. Accordingly, such
stretch of wire is relatively short and taut and, therefore,
remains controllable throughout the process.
FIG. 6 illustrates another key step in the method of this invention
by which the gripper jaws 56 are first moved, as indicated by the
arrow 76 in FIG. 6, in a generally circular, counterclockwise,
direction to extend the portion of the coil lead 38 exiting from
the trough 74 around the outer side of the tang 34, thereby hooking
or looping the coil lead 38 about an edge 78 of the tang 34 and
around the stretch, designated 80, of the coil lead 38 entering the
lead-receiving trough 74. The coil lead 38 is also thereby extended
over the upper edge, designated 84 in FIGS. 7 through 9, of the
second terminal leg 32.
The jaws 56 are then moved generally downwardly, as indicated by
the arrow 82 in FIG. 7, whereupon the coil lead 38 is extended
downwardly along the backside of the terminal leg 32 and brought
into engagement with the upper edge 84. By virtue of the preceding
steps, the coil lead 38 is looped around an edge of the tang 34,
extended over itself, and also bent around the upper edge 84 of the
terminal leg 32.
With reference to FIGS. 8 and 9, the free end of the coil lead 38
is now severed from the portion thereof connected to the terminal
leg 32 by the simple expedient of pulling downwardly on the free
end of the coil lead 38 with sufficient force that the coil lead 38
is stretched over the top rear corner 86 of the terminal leg 32 to
the point that it breaks at that corner. This step is accomplished
by moving the jaws 56 downwardly as shown by the arrow 88 in FIG. 8
until the coil lead 38 breaks against the terminal leg corner 86,
leaving a severed wire remnant 90 in the jaws 56. Prior to the
downward, wire-severing movement of the jaws 56, their clamping
pressure is increased so that they firmly clamp the free end of the
coil lead 38 and will not slide off the coil lead 38 as the lead is
being stretched and broken. It may be noted in FIG. 9, which shows
the final connection of the coil lead 38 to the terminal leg 32,
that the severed end of the lead 38 has a somewhat reduced diameter
because of the stretching of the lead that occurs prior to
breakage. The coil lead 38 is now tightly wrapped around the
terminal tang 34 in a configuration resembling the Greek letter
alpha.
During the wire-breaking movement of the gripper jaws 56
illustrated in FIG. 8, the jaws should be so oriented that the
stretch of the coil lead 38 between the jaws 56 and the terminal
corner 86 engages over only smoothly curved surfaces of the gripper
jaws 56 to insure that the coil lead does not break at a jaw
surface rather than at the terminal corner 86. As an alternative,
the gripper jaws 56 could be so oriented that the such stretch of
the coil lead 38 extends vertically between the mutually
confronting jaw surfaces that clamp the lead so that such stretch
of the lead does not lie along an outside surface of either of the
jaws 56.
After the connection and breaking of the coil lead 38 as described
above, the griper jaws 56 may be spread apart to release the wire
remnant 90 and then repositioned to sequentially connect and sever
the coil leads 40, 42, and 44. The connection and severing of the
coil leads 40, 42, and 44 to the other terminals will proceed using
the method described above, except for differences in movements of
the jaws 56 necessitated by the different locations of the coil
leads relative to their respective terminals. Thus, for example,
the first movement of the gripper jaws 56 after gripping the coil
lead 40 would be downwardly rather than upwardly as in the case of
the coil lead 38.
FIG. 10 shows a modified terminal arrangement wherein a coil lead
110 is connected to a plate-like terminal 112 mounted in a socket
114 on a stator core 116. Here the lead 110 is extended directly
from its associated coil 118 around a tang 120 struck from a first
face 122 of the the terminal 112 and then to the top corner 124 of
the second face 126. The method of connecting the coil lead 110 and
breaking it at the corner 124 is that same as that described above,
except that there is no protuberance, such as the protuberance 68,
on the sockett 114 about which the coil lead 110 must be coursed.
Accordingly, the wire grippers are first manipulated to grip the
coil lead 110 and then moved to lay the coil lead between the tang
120 and the first terminal face 122. The remaining steps to connect
and sever the wire lead 110 are the same as those described above
with respect to the coil lead 38 after it is laid into the trough
74.
Tests have shown that coil lead connected and broken in accordance
with this invention are connected to their terminals with
sufficient reliability that the method of this invention may be
used in the mass production of stators. Furthermore, the lead
connections to the terminals are sufficiently secure that there is
no need to peen the tang over the lead at the completion of the
lead connection and breaking steps of this invention. Instead, the
stator may undergo further processing prior to the fusion of the
leads to the terminals without additional attention to the leads
and terminals.
Although the presently preferred embodiments of this invention have
been described, it will be understood that within the purview of
this invention various changes may be made within the scope of the
appended claims.
* * * * *